Glass article and method for forming the same

ABSTRACT

A method includes forming a glass article. The glass article includes a core and a clad adjacent to the core. The core includes a first glass composition. The clad includes a second glass composition different than the first glass composition. A degradation rate of the second glass composition in a reagent is greater than a degradation rate of the first glass composition in the reagent.

This application claims the benefit of priority under 35 U.S.C. § 371 ofInternational Application No. PCT/US2015/020059 filed on Mar. 12, 2015,which claims the benefit of priority of U.S. Provisional Application No.61/952,580 filed on Mar. 13, 2014 and Provisional Application No.61/989,717 filed on May 7, 2014, the content of each of which isincorporated herein by reference in its entirety.

BACKGROUND

1. Field

This disclosure relates to glass articles, and more particularly tolaminated glass articles comprising at least two glass layers havingdifferent degradation rates in a reagent and use of such glass articlesfor making processed glass articles with defect-free surfaces.

2. Technical Background

Processing or handling a glass article such as a glass rod or a glasssheet can damage the surface of the glass article. For example, a glasssheet can be molded to form a molded glass article having any of avariety of different three-dimensional shapes. During the moldingprocess, any defects present on the surface of the mold can betransferred to the surface of the molded glass article. The resultingdefects can be removed from the molded glass article by grinding andpolishing, which can be time-consuming, expensive, and awkward toperform, especially on non-flat surfaces. Alternatively, the defects canbe removed by acid-etching, which can leave the molded glass articlewith a visibly roughened surface.

SUMMARY

Disclosed herein are glass articles and methods for forming glassarticles. The glass articles comprise a core and a clad. The corecomprises a core glass composition, and the clad comprises a clad glasscomposition different than the core glass composition. A degradationrate of the clad glass composition in a reagent is greater than adegradation rate of the core glass composition in the reagent.

Disclosed herein is a method comprising forming a glass article. Theglass article comprises a core and a clad adjacent to the core. The corecomprises a core glass composition. The clad comprises a clad glasscomposition different than the core glass composition. The clad glasscomposition comprises from about 45 mol % to about 60 mol % SiO₂ andfrom about 8 mol % to about 19 mol % Al₂O₃. The clad glass compositionis substantially free of As and Cd. A degradation rate of the clad glasscomposition in a reagent is at least 10 times greater than a degradationrate of the core glass composition in the reagent.

Also disclosed herein is a method comprising forming a laminated glasssheet comprising a core layer disposed between a first cladding layerand a second cladding layer. The first cladding layer and the secondcladding layer independently comprise from about 45 mol % to about 60mol % SiO₂ and from about 8 mol % to about 19 mol % Al₂O₃. The firstcladding layer and the second cladding layer are substantially free ofAs and Cd. An outer surface of the laminated glass sheet is contactedwith a processing unit. The first cladding layer and the second claddinglayer are contacted with a reagent to at least partially remove thefirst cladding layer and the second cladding layer. A ratio of adegradation rate of each of the first cladding layer and the secondcladding layer in the reagent to a degradation rate of the core layer inthe reagent is at least 10.

Also disclosed herein is a glass article comprising a core and a cladadjacent to the core. The core comprises a core glass composition. Theclad comprises a clad glass composition. The clad glass compositioncomprises from about 45 mol % to about 60 mol % SiO₂, from about 8 mol %to about 19 mol % Al₂O₃, a coefficient of thermal expansion (CTE) offrom about 50×10⁻⁷/° C. to about 95×10⁻⁷/° C., and a liquidus viscosityof at least about 50 kP. The clad glass composition is substantiallyfree of Pb, As, and Cd. A ratio of a degradation rate of the clad glasscomposition in a reagent to a degradation rate of the core glasscomposition in the reagent is at least about 10.

Also disclosed herein is a glass article comprising a core and a cladsubstantially enveloping the core. The core comprises a core glasscomposition. The clad comprises a clad glass composition. The clad glasscomposition comprises from about 45 mol % to about 60 mol % SiO₂, fromabout 8 mol % to about 19 mol % Al₂O₃, a coefficient of thermalexpansion (CTE) of from about 50×10⁻⁷/° C. to about 95×10⁻⁷/° C., and aliquidus viscosity of at least about 50 kP. The clad glass compositionis substantially free of As and Cd. Contacting the glass article with areagent for about 0.5 hr to about 10 hr causes the clad to be at leastpartially removed from the core and exposes an outer surface of thecore.

Additional features and advantages will be set forth in the detaileddescription which follows, and in part will be readily apparent to thoseskilled in the art from that description or recognized by practicing theembodiments as described herein, including the detailed descriptionwhich follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are merely exemplary, and areintended to provide an overview or framework to understanding the natureand character of the claims. The accompanying drawings are included toprovide a further understanding, and are incorporated in and constitutea part of this specification. The drawings illustrate one or moreembodiment(s), and together with the description serve to explainprinciples and operation of the various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial cross-sectional view of one exemplary embodiment ofa glass article.

FIG. 2 is a partial cross-sectional view of another exemplary embodimentof a glass article.

FIG. 3 is a cross-sectional view of one exemplary embodiment of anapparatus for forming a glass article.

FIG. 4 is a partial cross-sectional view of the glass article shown inFIG. 1 with defects formed in outer surfaces thereof.

FIG. 5 is a partial cross-sectional view of the glass article shown inFIGS. 1 and 3 with clad removed.

FIG. 6 illustrates a simulated response of one exemplary embodiment of aglass sheet to being contacted with one exemplary embodiment of aforming surface comprising a protrusion.

FIG. 7 is a graphical illustration of a predicted clad thicknesssufficient to avoid a visible defect in a core layer of one exemplaryembodiment of a glass sheet resulting from one exemplary protrusion of aforming surface.

FIG. 8 is a graphical illustration of a predicted clad thicknesssufficient to avoid a visible defect in a core layer of one exemplaryembodiment of a glass sheet resulting from another exemplary protrusionof a forming surface.

FIG. 9 is a graphical representation of a predicted clad thicknesssufficient to avoid a visible defect in a core layer of one exemplaryembodiment of a glass article as a function of the amplitude and thewidth of one exemplary protrusion of a forming surface.

FIG. 10 is a graphical representation of the degradation rates of oneexemplary core glass composition and one exemplary clad glasscomposition, expressed as etch thickness as a function of time.

FIG. 11 is a photograph of one exemplary embodiment of a molded glassarticle prior to removal of the clad.

FIG. 12 is a photograph of the molded glass article of FIG. 11 afterremoval of the clad.

FIG. 13 is a photograph of another exemplary embodiment of a moldedglass article following removal of the clad from half of the moldedglass article.

FIG. 14 is a photograph of another exemplary embodiment of a moldedglass article prior to removal of the clad.

FIG. 15 is a photograph of the molded glass article of FIG. 14 afterremoval of the clad.

DETAILED DESCRIPTION

Reference will now be made in detail to exemplary embodiments which areillustrated in the accompanying drawings. Whenever possible, the samereference numerals will be used throughout the drawings to refer to thesame or like parts. The components in the drawings are not necessarilyto scale, emphasis instead being placed upon illustrating the principlesof the exemplary embodiments.

As used herein, the term “liquidus viscosity” refers to the shearviscosity of a glass composition at the liquidus temperature of theglass composition.

As used herein, the term “liquidus temperature” refers to the highesttemperature at which devitrification occurs in a glass composition.

As used herein, the terms “coefficient of thermal expansion” or “CTE”refer to the coefficient of thermal expansion of a glass compositionaveraged over a temperature range from about 20° C. to about 300° C.

The term “substantially free,” when used herein to describe the absenceof a particular oxide component in a glass composition, means that thecomponent is absent from the glass composition or present in the glasscomposition in a trace amount of less than 0.2 mol %.

Throughout this disclosure, the concentrations of constituent components(e.g., SiO₂, Al₂O₃, B₂O₃, and the like) are given in mole percent (mol%) on an oxide basis, unless otherwise specified.

FIG. 1 is a cross-sectional view of one exemplary embodiment of a glassarticle comprising a core and a clad adjacent to the core. The clad canbe directly adjacent to the core or spaced from the core by one or moreintermediate glass layers. In some embodiments, the clad comprises anexterior shell at least partially enveloping the core. The clad can aidin protecting the core during processing and/or handling of the glassarticle as described herein. In the embodiment shown in FIG. 1, theglass article comprises a laminated glass sheet 100. Glass sheet 100 canbe planar as shown in FIG. 1 or non-planar. The core of glass sheet 100comprises a core layer 102. The core layer can comprise a single layeras shown in FIG. 1 or a plurality of layers. The clad of glass sheet 100comprises a first cladding layer 104 and a second cladding layer 106.Each of the first cladding layer and the second cladding layer cancomprise a single layer as shown in FIG. 1 or a plurality of layers.Core layer 102 is disposed between first cladding layer 104 and secondcladding layer 106. First cladding layer 104 and second cladding layer106 are exterior layers of glass sheet 100. Core layer 102 comprises afirst major surface and a second major surface opposite the first majorsurface. In some embodiments, first cladding layer 104 is fused to thefirst major surface of core layer 102. Additionally, or alternatively,second cladding layer 106 is fused to the second major surface of corelayer 102. The interface between first cladding layer 104 and core layer102 and/or between second cladding layer 106 and core layer 102 can befree of any bonding material such as, for example, an adhesive, acoating layer, or any other non-glass material added or configured toadhere the respective cladding layer to the core layer. Thus, one orboth of cladding layers 104 and 106 are fused directly to core layer 102and/or disposed directly adjacent to the core layer. In someembodiments, the glass sheet comprises one or more intermediate layersdisposed between the core layer and the first cladding layer and/orbetween the core layer and the second cladding layer. For example, theintermediate layers comprise intermediate glass layers and/or diffusionlayers formed at the interface of the core layer and the cladding layer.The diffusion layer can comprise a blended region comprising componentsof each layer adjacent to the diffusion layer. In some embodiments,glass sheet 100 comprises a glass-glass laminate (e.g., an in situ fusedmultilayer glass-glass laminate) in which the interfaces betweendirectly adjacent glass layers are glass-glass interfaces.

FIG. 2 is a cross-sectional view of another exemplary embodiment of aglass article comprising a core and a clad adjacent to the core. In theembodiment shown in FIG. 2, the glass article comprises a laminatedglass sheet 110. Glass sheet 110 is similar to glass sheet 100 describedwith reference to FIG. 1. For example, glass sheet 110 comprises a corelayer 112 disposed between a first cladding layer 114 and a secondcladding layer 116. Core layer 112 comprises a plurality of layers. Forexample, in the embodiment shown in FIG. 2, core layer 112 comprises aninner core layer 112 a disposed between a first outer core layer 112 band a second outer core layer 112 c. First outer core layer 112 b isdisposed between first cladding layer 114 and inner core layer 112 a.Second outer core layer 112 c is disposed between second cladding layer116 and inner core layer 112 a.

In some embodiments, the core comprises a core glass composition, andthe clad comprises a clad glass composition that is different than thecore glass composition. For example, in the embodiment shown in FIG. 1,core layer 102 comprises the core glass composition, and each of firstcladding layer 104 and second cladding layer 106 comprises the cladglass composition. In other embodiments, first cladding layer 104comprises a first clad glass composition, and second cladding layer 106comprises a second clad glass composition that is different than thecore glass composition and/or the first clad glass composition. In theembodiment shown in FIG. 2, inner core layer 112 a comprises an innercore glass composition, and each of first outer core layer 112 b andsecond outer core layer 112 c comprises an outer core glass compositionthat is different than the inner core glass composition. In otherembodiments, first outer core layer 112 b comprises a first outer coreglass composition, and second outer core layer 112 c comprises a secondouter core glass composition that is different than the inner core glasscomposition and/or the first outer core glass composition.

The glass article can be formed using a suitable process (e.g., afusion-draw, down-draw, slot-draw, up-draw, rolling, or offlinelamination process). In some embodiments, the glass article is formedusing a fusion-draw process. FIG. 3 illustrates one exemplary embodimentof a laminate overflow distributor apparatus 200 that can be used toform a glass article such as, for example, glass sheet 100 using afusion-draw process. Apparatus 200 is configured generally as describedin U.S. Pat. No. 4,214,886, which is incorporated by reference herein inits entirety. Apparatus 200 comprises a lower overflow distributor 220positioned beneath an upper overflow distributor 240. Lower overflowdistributor 220 comprises a trough 222. A first glass composition 224(e.g., the core glass composition) is melted and fed into trough 222 ina viscous state. First glass composition 224 forms core layer 102 ofglass sheet 100. Upper overflow distributor 240 comprises a trough 242.A second glass composition 244 (e.g., the clad glass composition) ismelted and fed into trough 242 in a viscous state. Second glasscomposition 244 forms cladding layers 104 and 106 of glass sheet 100.

First glass composition 224 overflows trough 222 and flows down opposingouter forming surfaces 226 and 228 of lower overflow distributor 220.Outer forming surfaces 226 and 228 converge at a draw line 230. Theseparate streams of first glass composition 224 flowing down respectiveouter forming surfaces 226 and 228 of lower overflow distributor 220converge at draw line 230 where they are fused together to form corelayer 102 of glass sheet 100.

Second glass composition 244 overflows trough 242 and flows downopposing outer forming surfaces 246 and 248 of upper overflowdistributor 240. Second glass composition 244 is deflected outward byupper overflow distributor 240 such that the second glass compositionflows around lower overflow distributor 220 and contacts first glasscomposition 224 flowing over outer forming surfaces 226 and 228 of thelower overflow distributor. The separate streams of second glasscomposition 244 are fused to the respective separate streams of firstglass composition 224 flowing down respective outer forming surfaces 226and 228 of lower overflow distributor 220. Upon convergence of thestreams of first glass composition 224 at draw line 230, second glasscomposition 244 forms cladding layers 104 and 106 of glass sheet 100.

In some embodiments, glass sheet 100 is part of a glass ribbon travelingaway from draw line 230 of lower overflow distributor 220 as shown inFIG. 3. The glass ribbon is severed to separate glass sheet 100therefrom. Thus, glass sheet 100 is cut from the glass ribbon. The glassribbon can be severed using a suitable technique such as, for example,scoring, bending, thermally shocking, and/or laser cutting.

In some embodiments, the glass article (e.g., glass sheet 100 or glasssheet 110) comprises a thickness of at least about 0.05 mm, at leastabout 0.1 mm, at least about 0.2 mm, at least about 0.3 mm, or at leastabout 0.5 mm. Additionally, or alternatively, the glass articlecomprises a thickness of at most about 12.5 mm, at most about 10 mm, atmost about 5 mm, at most about 3 mm, at most about 1.5 mm, or at mostabout 0.5 mm. For example, the glass article comprises a thickness offrom about 0.2 mm to about 12.5 mm. Additionally, or alternatively, thecore (e.g., core layer 102 or core layer 112) comprises a thickness offrom about 0.1 mm to about 12 mm. Additionally, or alternatively, theclad (e.g., each of first cladding layer 104 and second cladding layer106) comprises a thickness of from about 0.025 mm to about 0.25 mm.

In some embodiments, a ratio of a thickness of the core layer (e.g.,core layer 102 or core layer 112) to a thickness of the glass sheet isat least about 0.7, at least about 0.8, at least about 0.85, at leastabout 0.9, or at least about 0.95. Additionally, or alternatively, aratio of a thickness of inner core layer 112 a to a thickness of corelayer 112 is at least about 0.7, at least about 0.8, at least about0.85, at least about 0.9, or at least about 0.95. In some embodiments,the ratio of the thickness of the core (e.g., core layer 102 or corelayer 112) to the thickness of the clad (e.g., the combined thickness ofcladding layers 104 and 106) is at least about 1, at least about 3, atleast about 5, at least about 7, or at least about 9. Additionally, oralternatively, the ratio of the thickness of the core to the thicknessof the clad is at most about 20, at most about 15, or at most about 10.

Although glass sheet 100 shown in FIG. 1 comprises three layers, andglass sheet 110 shown in FIG. 2 comprises five layers, other embodimentsare included in this disclosure. In other embodiments, a glass sheet canhave a determined number of layers, such as two, four, or more layers.For example, one of the first cladding layer or the second claddinglayer can be omitted such that the glass sheet comprises a two-layerglass sheet. A glass sheet comprising two layers can be formed using twooverflow distributors positioned so that the two layers are joined whiletraveling away from the respective draw lines of the overflowdistributors or using a single overflow distributor with a dividedtrough so that two glass compositions flow over opposing outer formingsurfaces of the overflow distributor and converge at the draw line ofthe overflow distributor. A glass sheet comprising four or more layerscan be formed using additional overflow distributors and/or usingoverflow distributors with divided troughs. Thus, a glass sheet having adetermined number of layers can be formed by modifying the overflowdistributor accordingly. In some embodiments, one or more intermediatelayers are disposed between the core layer and a cladding layer. Thus,the cladding layers can be exterior layers regardless of the totalnumber of layers included in the laminated glass sheet.

In some embodiments, the glass article can be configured as a glass rodor filament comprising an elongate core and a cladding layer disposedabout the core. The glass article can have a suitable cross-sectionalshape such as, for example, circular, elliptical, triangular,rectangular, or another polygonal or non-polygonal shape.

In some embodiments, the glass article comprises a pristine outersurface. The pristine outer surface is substantially smooth and uniform.In the embodiment shown in FIG. 1, glass sheet 100 comprises pristine(i.e., substantially smooth and uniform) outer surfaces (i.e., the outersurfaces of first and second cladding layers 104 and 106). Similarly, inthe embodiment shown in FIG. 2, glass sheet 110 comprises pristine outersurfaces (i.e., the outer surfaces of first and second cladding layers114 and 116). In some embodiments, the pristine outer surfaces of theglass sheet are formed without grinding or polishing. For example, thepristine outer surfaces are formed during the fusion-draw process asdescribed herein. The pristine outer surfaces can be a result of thelack of contact between the outer surfaces and apparatus 200 duringformation of the glass sheet.

In some embodiments, the core of the glass article comprises a pristineouter surface. The interface between the core and the clad issubstantially smooth and uniform. In the embodiment shown in FIG. 1,core layer 102 of glass sheet 100 comprises pristine (e.g.,substantially smooth and uniform) outer surfaces (i.e., the interfacesbetween the core layer and each of first and second cladding layers 104and 106). Similarly, in the embodiment shown in FIG. 2, core layer 112of glass sheet 110 comprises pristine outer surfaces (i.e., theinterfaces between the core layer and each of first and second claddinglayers 114 and 116). In some embodiments, the pristine outer surfaces ofthe core layer are formed during the fusion-draw process as describedherein.

In some embodiments, the glass article is subjected to processing and/orhandling during which the outer surface of the glass article is engagedby one or more glass processing units. The glass processing unit cancomprise suitable equipment used during processing, transportation,and/or storage of the glass article such as, for example, a grippingunit (e.g., a suction cup or a clamp), a conveying unit (e.g., aconveyor, a cart, or a rack), a forming unit (e.g., a mold or a die), oranother type of equipment that engages the glass article. FIG. 4 is apartial cross-sectional view of the glass article shown in FIG. 1following engagement by a processing unit. Engagement of the glassarticle by the glass processing unit may damage the outer surface of theglass article so that the outer surface of the glass article is nolonger pristine. For example, in some embodiments, the outer surface ofthe glass article comprises defects (e.g., indentations, protrusions, orscratches) following engagement by the processing unit such that theouter surface is non-smooth and/or non-uniform.

In some embodiments, the outer surface of glass sheet 100 is contactedby a forming unit. The forming unit comprises a formed surface, andglass sheet 100 is maintained at a sufficiently high temperature thatcontacting the glass sheet with the forming unit imparts a shape to theglass sheet that is complementary to the shape of the formed surface.The forming unit engages glass sheet 100 to form a molded glass article.In some embodiments, the formed surface of the forming unit comprisesimperfections (e.g., indentations or protrusions) that impart defects tothe outer surface of glass sheet 100 during forming of the molded glassarticle. The imperfections on the formed surface can be the result, forexample, of manufacturing defects, wear on the formed surface caused byrepeated use, or foreign material disposed on the formed surface. Insome embodiments, the outer surface of glass sheet 100 is no longerpristine following engagement by the forming unit. For example, themolded glass article comprises a non-smooth and/or non-uniform outersurface as shown in FIG. 4 following engagement by the forming unit.

In some embodiments, the defects on the outer surface of the glassarticle are confined to the clad and do not extend into the core. Forexample, the defects are confined to first cladding layer 104 and/orsecond cladding layer 106 and do not extend into core layer 102 as shownin FIG. 4. The clad protects the core from damage during handling and/orprocessing. In some embodiments, the clad is partially or substantiallyentirely removed from the core to expose the outer surface of the core.FIG. 5 is a partial cross-sectional view of the glass article shown inFIGS. 1 and 4 following removal of the clad. The damaged clad is removedfrom the core to expose the pristine outer surface of the core. Forexample, in some embodiments, first cladding layer 104 and secondcladding layer 106 are removed from core layer 102 to expose the outersurface of the core layer as shown in FIG. 5. The exposed outer surfaceof core layer 102 comprises a pristine surface. Removing first andsecond cladding layers 104 and 106 removes the defects in the first andsecond cladding layers from the glass article, leaving the glass articlewith a pristine surface substantially free of the defects imparted tothe glass article by the processing unit.

FIG. 6 illustrates a simulated response of glass sheet 100 to beingcontacted with one exemplary embodiment of a forming surface 300comprising a protrusion 302. In some embodiments, first cladding layer104 at least partially absorbs the effect of protrusion 302, therebyminimizing the defect of core layer 102 at the interface between thecore layer and the first cladding layer resulting from protrusion 302.In other words, the defect in core layer 102 at the interface is widerand smaller in amplitude compared to the defect in first cladding layer104 at the surface of glass sheet 100 resulting from protrusion 302.

The size of the defect in the core layer resulting from the protrusionon the forming surface relative to the size of the protrusion depends ona core to clad viscosity ratio and the clad thickness. FIGS. 7 and 8 aregraphical illustrations of predicted clad thickness sufficient to avoida visible defect in core layer 102 resulting from protrusion 302 onforming surface 300. The data presented in FIG. 7 are calculated basedon protrusion 302 having an amplitude of 5 μm and a width of 20 μm. Thevisibility of the defect in the core layer is related to the slope ofthe defect. Curve 310 corresponds to the defect in core layer 102 havinga slope of 1/1000. Curve 312 corresponds to the defect in core layer 102having a slope of 1/5000. The data presented in FIG. 8 are calculatedbased on protrusion 302 having an amplitude of 20 μm and a width of 20μm. Curve 320 corresponds to the defect in core layer 102 having a slopeof 1/1000. Curve 322 corresponds to the defect in core layer 102 havinga slope of 1/5000. FIGS. 7-8 illustrate that the clad thicknesssufficient to avoid a visible defect in the core decreases as the coreto clad viscosity ratio increases. Thus, a thinner clad is sufficient toavoid a visible defect in the core at higher core to clad viscosityratios.

In some embodiments, at least one of the clad thickness or the core toclad viscosity ratio is adjusted based on a surface condition of theforming surface. For example, the surface condition comprises anexpected protrusion size or surface roughness. Thus, the clad thicknessand/or the core to clad viscosity ratio is adjusted based on the surfacecondition of the forming surface to achieve a core that is substantiallyfree of visible defects. For example, the core layer can be made moreresistant to visible defects by increasing the core viscosity,decreasing the clad viscosity, and/or increasing the clad thickness. Theability to adjust the resistance of the core layer to visible defectscan enable the glass sheet to be tailored to a mold surface. Forexample, the core viscosity can be increased with increasing mold wear.Additionally, or alternatively, the clad viscosity can be decreased withincreasing mold wear. Additionally, or alternatively, the clad thicknesscan be increased with increasing mold wear. The mold wear can represent,for example, the length of time that a mold is in service or a number ofglass articles formed in the mold.

In some embodiments, glass sheet 110 is engaged by a glass processingunit as described herein with reference to glass sheet 100. For example,the outer surface of glass sheet 110 is contacted by a forming unit thatimparts defects to the outer surface of the glass sheet during formingof the molded glass article. In some embodiments, the defects areconfined to first cladding layer 114 and/or second cladding layer 116and do not extend into core layer 112. In some embodiments, firstcladding layer 114 and second cladding layer 116 are at least partiallyremoved from core layer 112 to expose the outer surface of the corelayer, which can comprise a pristine surface.

Protection of the core by the clad can prevent damage from being causedto the core of the glass article during handling and/or processing.Damage caused to the glass article can be removed by removing the clad.Protection of the core by the clad can enable use of a forming unit withimperfections on the formed surface thereof. This can lengthen theamount of time that the forming unit can be used before replacement orrepair or reconditioning of the formed surface (i.e., the useful life ofthe forming unit). Protection of the core by the clad can enableproduction of the molded glass article with a pristine outer surfacewithout grinding or polishing the molded glass article.

In some embodiments, the clad is less durable than the core. Forexample, in the embodiment shown in FIG. 1, first cladding layer 104 andsecond cladding layer 106 are less durable than core layer 102. In theembodiment shown in FIG. 2, first cladding layer 114 and second claddinglayer 116 are less durable than first outer core layer 112 b and secondouter core layer 112 c. In some embodiments, inner core layer 112 a isenveloped within first and second outer core layers 112 b and 112 c.Because inner core layer 112 a is protected by first and second outercore layers 112 b and 112 c, the inner core layer can be more durable orless durable than first and second cladding layers 114 and 116 or firstand second outer core layers 112 b and 112 c. The clad glass composition(e.g., of first and second cladding layers 104 and 106 or of first andsecond cladding layers 114 and 116) comprises a greater degradation ratein a reagent than the core glass composition (e.g., of core layer 102 orof first and second outer core layers 112 b and 112 c). In someembodiments, the degradation rate of the clad glass composition in thereagent is at least 10 times greater than the degradation rate of thecore glass composition in the reagent. In some embodiments, the glassarticle is contacted with the reagent to remove at least a portion ofthe clad from the core and expose the outer surface of the core. Thedifference in durability between the clad and the core can enable theclad to be removed from the core by contacting the glass article withthe reagent to degrade or dissolve the clad without substantiallydegrading or dissolving the core.

The reagent comprises a suitable component capable of degrading ordissolving the glass article (e.g., the clad and/or the core). Forexample, the reagent comprises an acid, a base, another suitablecomponent, or a combination thereof. In some embodiments, the reagentcomprises an acid such as, for example, a mineral acid (e.g., HCl, HNO₃,H₂SO₄, H₃PO₄, H₃BO₃, HBr, HClO₄, or HF), a carboxylic acid (e.g.,CH₃COOH), or a combination thereof. For example, in some embodiments,the reagent comprises HCl (e.g., 50 vol % HCl in water). Additionally,or alternatively, the reagent comprises HNO₃. In some embodiments, thereagent comprises a base such as, for example, LiOH, NaOH, KOH, RbOH,CsOH, Ca(OH)₂, Sr(OH)₂, Ba(OH)₂, or a combination thereof.

In some embodiments, the reagent is substantially free of HF. HF reactswith many different oxides, and therefore, is highly reactive with mostglass compositions. For example, HF reacts with silicon dioxide to formgaseous or water-soluble silicon fluorides. Contacting the core of theglass article with a reagent comprising HF may result in reaction of theHF with the core, which can cause roughening or marring of the coresurface. Using a reagent that is substantially free of HF may preventsubstantial reaction of the reagent with the core to enable removal ofthe clad from the core without damaging the core surface.

In some embodiments, the glass article is contacted with the reagent toat least partially remove the clad from the core as described herein.Upon removal of the clad, the core can be at least partially exposed.For example, the core is at least partially exposed in response tocontacting the laminated glass article with the reagent for at leastabout 0.1 hr, at least about 0.5 hr, at least about 1 hr, or at leastabout 2 hr. Additionally, or alternatively, the core is at leastpartially exposed in response to contacting the laminated glass articlewith the reagent for at most about 10 hr, at most about 5 hr, or at mostabout 2 hr. The conditions under which the glass article is contactedwith the reagent (e.g., the concentration of the reagent, thetemperature, and/or the use of ultrasonic agitation) can be adjusted toadjust the rate of degradation of the clad.

In some embodiments, the reagent comprises a first reagent and a secondreagent. The glass article is contacted with the first reagent to removea first portion of the clad from the core and then contacted with thesecond reagent to remove a second portion of the clad from the core. Insome embodiments, the first reagent comprises HF. The glass article iscontacted with the first reagent for a sufficiently short time that thecore remains substantially enveloped within the clad after contactingthe glass article with the first reagent and before contacting the glassarticle with the second reagent. The first reagent comprising HF can beused to degrade the first portion of the clad relatively quickly withoutcontacting the core with the first reagent, which can damage the outersurface of the core. In some embodiments, the second reagent issubstantially free of HF. Additionally, or alternatively, thedegradation rate of the clad in the second reagent is greater than thedegradation rate of the core in the second reagent as described herein.The core can be contacted with the second reagent (e.g., followingremoval of the second portion of the clad) without damaging the outersurface of the core.

In some embodiments, the outer surface of the core is contacted by thereagent following removal of the clad (e.g., substantially complete orpartial removal of the clad). Although the core is more durable than theclad, in some embodiments, the reagent degrades the core to some degree.Upon contacting the core with the reagent, at least a portion of thecore can be degraded by the reagent such that an outermost portion ofthe outer surface of the core is removed. For example, the removedoutermost portion is up to about 1 μm thick. This can aid instrengthening the core, for example, by blunting fracture tips at thesurface of the core.

In some embodiments, ion exchange is caused between the clad and thecore. Smaller cations (e.g., monovalent alkali metal cations or divalentalkaline earth metal cations) present in the core (e.g., core layer 102or first and second outer core layers 112 b and 112 c) are replaced withlarger cations (e.g., monovalent alkali metal cations, divalent alkalineearth metal cations, or Ag⁺) present in the clad (e.g., first and secondcladding layers 104 and 106 or first and second cladding layers 114 and116). For example, in some embodiments, Na⁺ present in the core isreplaced with K⁺ present in the clad. The smaller cations and the largercations can have the same valence or oxidation state. The replacement ofsmaller cations with larger cations creates a surface layer in the corethat is under compression or compressive stress (CS). The surface layerextends into the interior or bulk of the core to a depth of layer (DOL).This can aid in increasing the strength of the glass article followingremoval of the clad. The compressive stress in the surface layer isbalanced by a tensile stress (TS) or central tension in an interiorregion of the core. The ion exchange can be caused by a suitable methodsuch as, for example, heating the glass article prior to removing theclad from the core.

In some embodiments, the first and second outer core layers 112 b and112 c are ion exchangeable. Thus, the glass article can be subjected toan ion exchange process after removal of the clad to create a surfacelayer in the outer core layers that is under compression or compressivestress. The ion exchange process can include a suitable ion exchangeprocess including, for example, contacting the glass article with amolten salt.

In some embodiments, each of the core glass composition and the cladglass composition comprises properties (e.g., liquidus viscosity,liquidus temperature, and CTE) suitable for formation of the glassarticle (e.g., the laminated glass sheet 100 or the laminated glasssheet 110) using a fusion-draw process as described herein.Additionally, or alternatively, the clad glass composition is lessdurable than the core glass composition as described herein.

In some embodiments, the core glass composition comprises from about 62mol % to about 77 mol % SiO₂. Additionally, or alternatively, the coreglass composition comprises from about 2 mol % to about 13 mol % Al₂O₃.Additionally, or alternatively, the core glass composition comprisesfrom about 0 mol % to about 10 mol % B₂O₃. Additionally, oralternatively, the core glass composition comprises an alkali metaloxide selected from the group consisting of Na₂O, K₂O, and combinationsthereof. For example, the core glass composition comprises from about 0mol % to about 15 mol % Na₂O and/or from about 0 mol % to about 12 mol %K₂O. Additionally, or alternatively, the core glass compositioncomprises an alkaline earth oxide selected from the group consisting ofCaO, MgO, SrO, BaO, and combinations thereof. For example, the coreglass composition comprises from about 0 mol % to about 1 mol % CaO,from about 2 mol % to about 7 mol % MgO from about 0 mol % to about 7mol % SrO, and/or from about 0 mol % to about 3 mol % BaO. Additionally,or alternatively, the core glass composition comprises from about 0 mol% to about 1 mol % SnO₂. In some embodiments, the difference between thealkali metal oxide (R₂O) concentration of the core glass composition andthe Al₂O₃ concentration of the core glass composition is from about 1 toabout 9.

Although exemplary embodiments of the core glass composition aredescribed herein, the core glass composition can comprise suitablecomponents in suitable amounts such that the core glass composition iscompatible with the clad glass composition for formation of the glassarticle as described herein. For example, the liquidus viscosity,liquidus temperature, and/or CTE of the core glass composition relativeto those of the clad glass composition can enable formation of the glassarticle using a fusion-draw process as described herein. Also forexample, the core glass composition can be more durable in the reagentthan the clad glass composition as described herein. Thus, the coreglass composition is not limited to the exemplary embodiments describedherein.

In the embodiments described herein, the clad glass compositioncomprises SiO₂, which can serve as a glass network former. For example,the second glass composition comprises from about 45 mol % to about 60mol % SiO₂. If the concentration of SiO₂ is too low, the clad glasscomposition can be incompatible with Zr, which is a common componentfound in fusion-draw equipment (e.g., in refractory). If theconcentration of SiO₂ is too high, the clad glass composition can havean undesirably high durability and can have a sufficiently high meltingpoint to adversely impact the formability of the glass.

In the embodiments described herein, the clad glass compositioncomprises Al₂O₃, which can serve as a glass network former. For example,the clad glass composition comprises from about 8 mol % to about 19 mol% Al₂O₃. The presence of Al₂O₃ can reduce the liquidus temperature ofthe clad glass composition, thereby increasing the liquidus viscosity ofthe clad glass composition. If the concentration of Al₂O₃ is too low,the clad glass composition can be undesirably soft (e.g., the strainpoint can be undesirably low) and can have an undesirably high CTE. Ifthe concentration of Al₂O₃ is too high, the clad glass composition canbe incompatible with Zr and can have an undesirably high durability.

In some embodiments, the clad glass composition comprises B₂O₃, whichcan serve as a glass network former. For example, the clad glasscomposition comprises from about 0 mol % to about 25 mol % B₂O₃. Thepresence of B₂O₃ can reduce the durability of the second glasscomposition. Additionally, or alternatively, the presence of B₂O₃ canreduce the viscosity and the liquidus temperature of the clad glasscomposition. For example, increasing the concentration of B₂O₃ by 1 mol% can decrease the temperature required to obtain an equivalentviscosity by about 10° C. to about 14° C., depending on the glasscomposition. However, increasing the concentration of B₂O₃ by 1 mol %can lower the liquidus temperature by about 18° C. to about 22° C.,depending on the glass composition. Thus, B₂O₃ can reduce the liquidustemperature of the glass composition more rapidly than it decreases theliquidus viscosity. If the concentration of B₂O₃ is too low, the cladglass composition can have an undesirably high durability. If theconcentration of B₂O₃ is too high, the clad glass composition can beundesirably soft.

In some embodiments, the clad glass composition comprises an alkalimetal oxide selected from the group consisting of Li₂O, Na₂O, K₂O, Rb₂O,CS₂O, and combinations thereof. For example, the clad glass compositioncomprises from about 0 mol % to about 8 mol % Li₂O. Additionally, oralternatively, the clad glass composition comprises from about 0 mol %to about 21 mol % Na₂O. Additionally, or alternatively, the clad glasscomposition comprises from about 0 mol % to about 12 mol % K₂O. Thealkali metal oxide can serve as a modifier. For example, the presence ofNa₂O can reduce the melting temperature of the clad glass composition,which can enhance the formability of the clad glass composition. Inembodiments comprising Na₂O, if the concentration of Na₂O is too low,the clad glass composition can have an undesirably high durability. Ifthe concentration of Na₂O is too high, the core glass composition canhave an undesirably high CTE.

In some embodiments, the clad glass composition comprises an alkalineearth oxide selected from the group consisting of CaO, MgO, SrO, andcombinations thereof. For example, the clad glass composition comprisesfrom about 0 mol % to about 10 mol % CaO. Additionally, oralternatively, the clad glass composition comprises from about 0 mol %to about 2 mol % MgO. Additionally, or alternatively, the clad glasscomposition comprises from about 0 mol % to about 2 mol % SrO.

In some embodiments, the clad glass composition comprises a fining agentselected from the group consisting of SnO₂, Sb₂O₃, Ce₂O₃, Cl (e.g.,derived from KCl or NaCl), and combinations thereof. For example, theclad glass composition comprises from about 0 mol % to about 0.1 mol %SnO₂.

In some embodiments, the clad glass composition comprises P₂O₅. Forexample, the clad glass composition comprises from about 0 mol % toabout 10 mol % P₂O₅.

In some embodiments, the clad glass composition comprises trace amountsof ZrO₂. For example, the clad glass composition comprises from about 0mol % to about 0.02 mol % ZrO₂.

In some embodiments, the clad glass composition is substantially free ofany or all of Pb, As, Cd, and Ba (i.e., constituents comprising thelisted elements). For example, the clad glass composition issubstantially free of Pb. Additionally, or alternatively, the clad glasscomposition is substantially free of As. Additionally, or alternatively,the clad glass composition is substantially free of Cd. Additionally, oralternatively, the clad glass composition is substantially free of Ba.

In some embodiments, the glass article can be formed using a fusion-drawprocess as described herein. In some embodiments, the CTE of the cladglass composition is less than or equal to the CTE of the core glasscomposition. For example, the CTE of the clad glass composition is fromabout 0×10⁻⁷/° C. to about 50×10⁻⁷/° C. less than the CTE of the coreglass composition, from about 0×10⁻⁷/° C. to about 30×10⁻⁷/° C. lessthan the CTE of the core glass composition, or from about 0×10⁻⁷/° C. toabout 10×10⁻⁷/° C. less than the CTE of the core glass composition. Insome embodiments, the clad glass composition comprises a CTE of fromabout 50×10⁻⁷/° C. to about 95×10⁻⁷/° C. In some embodiments, a liquidusviscosity of the clad glass composition is at least about 50 kP, atleast about 80 kP, or at least about 100 kP.

In some embodiments, the core layer of the glass article comprises aplurality of layers. For example, in the embodiment shown in FIG. 2, thecore layer comprises three layers. In some of such embodiments, the CTEof the outer core glass composition is less than or equal to the CTE ofthe inner core glass composition. For example, the CTE of the outer coreglass composition is from about 0×10⁻⁷/° C. to about 50×10⁻⁷/° C. lessthan the CTE of the inner core glass composition, from about 0×10⁻⁷/° C.to about 30×10⁻⁷/° C. less than the CTE of the inner core glasscomposition, or from about 0×10⁻⁷/° C. to about 10×10⁻⁷/° C. less thanthe CTE of the inner core glass composition. Thus, the first and secondouter core layers 112 b and 112 c comprise a compressive stress, andinner core layer 112 a comprises a tensile stress as a result of the CTEmismatch between the first and second outer core layers and the innercore layer. The compressive stress can aid in strengthening the glassarticle following removal of the clad to expose the core. In otherwords, the core comprises a strengthened core. In some embodiments, theCTE of each of the clad glass composition and the outer core glasscomposition is less than or equal to the CTE of the inner core glasscomposition.

In some embodiments, a ratio of the degradation rate of the clad glasscomposition in the reagent to the degradation rate of the core glasscomposition in the reagent is at least about 10, at least about 100, orat least about 1000. The degradation rate can be expressed, for example,in terms of weight loss relative to the original weight of the sampleafter contact with the reagent for a given period of time, in terms ofweight loss per surface area of the sample per unit of time upon contactwith the reagent, or another suitable manner. For example, thedegradation rate of the clad glass composition, expressed in terms ofweight loss relative to the original weight of the sample after contactby a 50 vol % aqueous HCl solution at 60° C. in an ultrasonic bath for30 min, is at least about 0.9%, at least about 5%, at least about 10%,or at least about 20%. Additionally, or alternatively, the degradationrate of the clad glass composition, expressed in terms of weight lossrelative to the original weight of the sample after contact by a 50 vol% aqueous HCl solution at 60° C. in an ultrasonic bath for 30 min, is atmost about 30%. Additionally, or alternatively, the degradation rate ofthe core glass composition, expressed in terms of weight loss relativeto the original weight of the sample after contact by a 50 vol % aqueousHCl solution at 60° C. in an ultrasonic bath for 30 min, is at mostabout 2%, at most about 0.1%, or at most about 0.01%.

Based on the foregoing, it should be understood that various embodimentsof relatively low durability glass compositions (e.g., for use as theclad glass composition of the glass article) are disclosed herein. Inone exemplary embodiment, the clad glass composition comprises fromabout 45 mol % to about 60 mol % SiO₂, from about 13 mol % to about 19mol % Al₂O₃, from about 5 mol % to about 23 mol % B₂O₃, and from about 3mol % to about 21 mol % Na₂O. Additionally, or alternatively, thedegradation rate of the clad glass composition, expressed in terms ofweight loss relative to the original weight of the sample after contactby a 50 vol % aqueous HCl solution at 60° C. in an ultrasonic bath for30 min, is from about 0.9% to about 29%. Additionally, or alternatively,the degradation rate of the clad glass composition is at least 10 timesgreater than the degradation rate of the core glass composition.

In another exemplary embodiment, the clad glass composition comprisesfrom about 55 mol % to about 59 mol % SiO₂, from about 12 mol % to about16 mol % Al₂O₃, from about 13 mol % to about 17 mol % B₂O₃, and fromabout 12 mol % to about 16 mol % Na₂O. Additionally, or alternatively,the degradation rate of the clad glass composition, expressed in termsof weight loss relative to the original weight of the sample aftercontact by a 50 vol % aqueous HCl solution at 60° C. in an ultrasonicbath for 30 min, is from about 1% to about 3%. Additionally, oralternatively, the degradation rate of the clad glass composition is atleast 10 times greater than the degradation rate of the core glasscomposition.

In another exemplary embodiment, the clad glass composition comprisesfrom about 47 mol % to about 51 mol % SiO₂, from about 13 mol % to about17 mol % Al₂O₃, from about 17 mol % to about 21 mol % B₂O₃, from about13 mol % to about 17 mol % Na₂O, and from about 0 mol % to about 4 mol %CaO. Additionally, or alternatively, the degradation rate of the cladglass composition, expressed in terms of weight loss relative to theoriginal weight of the sample after contact by a 50 vol % aqueous HClsolution at 60° C. in an ultrasonic bath for 30 min, is from about 22%to about 25%. Additionally, or alternatively, the degradation rate ofthe clad glass composition is at least 10 times greater than thedegradation rate of the core glass composition.

In some embodiments, a display (e.g., an LED or LCD display) comprises aglass article as described herein. For example, the display comprises acover glass comprising the glass article. In some embodiments, the coverglass comprises an integrated cover glass and color filter. In someembodiments, the cover glass comprises an integrated touch cover glass.

In some embodiments, an automotive glazing comprises a glass article asdescribed herein. The automotive glazing comprises, for example, awindshield, a sidelite (e.g., a door glass or a quarter window), a sunroof, a moon roof, a rear backlite, or another suitable glass or window.

In some embodiments, an architectural panel comprises a glass article asdescribed herein.

Various embodiments of the glass articles described herein can be usedfor a variety of applications including, for example, for cover glass orglass backplane applications in consumer or commercial electronicdevices including, for example, LCD and LED displays, computer monitors,and automated teller machines (ATMs); for touch screen or touch sensorapplications; for portable electronic devices including, for example,mobile telephones, personal media players, and tablet computers; forintegrated circuit applications including, for example, semiconductorwafers; for photovoltaic applications; for architectural glassapplications; for automotive or vehicular glass applications; forcommercial or household appliance applications; or for lightingapplications including, for example, solid state lighting (e.g.,luminaires for LED lamps).

EXAMPLES

Various embodiments will be further clarified by the following examples.

A plurality of core glass compositions, which can be suitable for use asa core of a glass article, were prepared according to the batchcompositions listed in Table 1 below. Batches of the oxide constituentcomponents were mixed, melted, and formed into glass plates. Theproperties of the glass melt and the resultant glass article weremeasured and the results are reported in Table 2. The degradation ratesreported in Table 2 are expressed in terms of weight loss relative tothe original weight of the sample after contact by a 50 vol % aqueousHCl solution at 60° C. in an ultrasonic bath for 30 min.

TABLE 1 Exemplary Core Glass Compositions SiO₂ Al₂O₃ B₂O₃ Na₂O K₂O MgOCaO SnO₂ (mol (mol (mol (mol (mol (mol (mol (mol Sample %) %) %) %) %)%) %) %) 1-1 66   10.26 0.58 14.23 2.37 5.75 0.59 0.21 1-2 69.18  8.470   13.92 1.16 6.54 0.53 0.19 1-3 68.84 10.63 0   14.86 0.02 5.43 0.040.17 1-4 67.45 12.69 3.67 13.67 0.02 2.36 0.03 0.09

TABLE 2 Properties of Exemplary Core Glass Compositions CTE LiquidusDegrad'n (×10⁻⁷/ Temp Liquidus Strain Pt Anneal Soft Pt Density SampleRate (%) ° C. (° C.) Visc (kP) (° C.) Pt (° C.) (° C.) (g/cm³) 1-1 0.0191.1 900 4250 551 600 843 2.452 1-2 0.01 83.6 950 1498 560 609 844 2.4441-3 0 80.1 1070 nm 602 652 900 2.432 1-4 0 74.6 1002 2210 589 644 9222.403

A plurality of clad glass compositions, which can be suitable for use asa clad of a glass article, were prepared according to the batchcompositions listed in Table 3 below. Batches of the oxide constituentcomponents were mixed, melted, and formed into glass plates. Theproperties of the glass melt and the resultant glass article weremeasured and the results are reported in Table 4. The degradation ratesreported in Table 4 are expressed in terms of weight loss relative tothe original weight of the sample after contact by a 50 vol % aqueousHCl solution at 60° C. in an ultrasonic bath for 30 min.

TABLE 3 Exemplary Clad Glass Compositions SiO₂ Al₂O₃ B₂O₃ CaO Li₂O Na₂OK₂O SnO₂ ZrO₂ P₂O₅ Sample (mol %) (mol %) (mol %) (mol %) (mol %) (mol%) (mol %) (mol %) (mol %) (mol %) 2-1  57 18.8 5 0 0 18.7 0.5 0.1 0.020 2-2  55 18.8 7 0 0 18.7 0.5 0.1 0.02 0 2-3  53 18.8 9 0 0 18.7 0.5 0.10.02 0 2-4  51 18.8 11 0 0 18.7 0.5 0.1 0.02 0 2-5  49 18.8 13 0 0 18.70.5 0.1 0.02 0 2-6  57 18.8 5 0 2 16.7 0.5 0.1 0.02 0 2-7  57 18.8 5 0 414.7 0.5 0.1 0.02 0 2-8  57 18.8 5 0 8 10.7 0.5 0.1 0.02 0 2-9  57 18 70 0 18 0 0.1 0 0 2-10 57 17 9 0 0 17 0 0.1 0 0 2-11 57 16 11 0 0 16 00.1 0 0 2-12 57 15 13 0 0 15 0 0.1 0 0 2-13 57.13 13.96 15.16 0.02 013.63 0 0.09 0 0 2-14 57 13 17 0 0 13 0 0.1 0 0 2-15 57.9 15 10 2 0 15 00.1 0 0 2-16 57.9 15 10 2 0 12 3 0.1 0 0 2-17 57.9 15 10 2 0 9 6 0.1 0 02-18 57.9 15 10 2 0 6 9 0.1 0 0 2-19 57.9 15 10 2 0 3 12 0.1 0 0 2-20 5515 13 2 0 6 9 0.1 0 0 2-21 55 15 13 2 0 9 6 0.1 0 0 2-22 55 15 13 2 0 123 0.1 0 0 2-23 55 15 13 2 0 15 0 0.1 0 0 2-24 53 15 15 2 0 6 9 0.1 0 02-25 53 15 15 2 0 9 6 0.1 0 0 2-26 53 15 15 2 0 12 3 0.1 0 0 2-27 53 1515 2 0 15 0 0.1 0 0 2-28 51 15 17 2 0 6 9 0.1 0 0 2-29 51 15 17 2 0 9 60.1 0 0 2-30 51 15 17 2 0 12 3 0.1 0 0 2-31 51 15 17 2 0 15 0 0.1 0 02-32 56 16 11 2 0 16 0 0.07 0 0 2-33 56 16 11 4 0 16 0 0.07 0 0 2-34 5618 7 1 0 18 0 0.07 0 0 2-35 56 18 7 2 0 18 0 0.07 0 0 2-36 56 18 7 4 018 0 0.07 0 0 2-37 55 17 11 0 0 17 0 0.07 0 0 2-38 54 17.5 11 0 0 17.5 00.07 0 0 2-39 53 18 11 0 0 18 0 0.07 0 0 2-40 55 16 13 0 0 16 0 0.07 0 02-41 54 16 14 0 0 16 0 0.07 0 0 2-42 53 16 15 0 0 16 0 0.07 0 0 2-43 5717.5 7 0 0 18.5 0 0.1 0 0 2-44 57 17 7 0 0 19 0 0.1 0 0 2-45 57 16.5 7 00 19.5 0 0.1 0 0 2-46 57 16 7 0 0 20 0 0.1 0 0 2-47 57 15.5 7 0 0 20.5 00.1 0 0 2-48 57 15 7 0 0 21 0 0.1 0 0 2-49 49 15 19 2 0 15 0 0.1 0 02-50 47 15 21 2 0 15 0 0.1 0 0 2-51 45 15 23 2 0 15 0 0.1 0 0 2-52 57 1611 10 0 16 0 0.1 0 0 2-53 57 14.5 14 0 0 14.5 0 0 0 0 2-54 57 15 13 2 015 0 0 0 0 2-55 57 14.5 14 2 0 14.5 0 0 0 0 2-56 57 14 15 2 0 14 0 0 0 02-57 57 17.5 7 1 0 18.5 0 0.1 0 0 2-58 57 17.5 7 2 0 18.5 0 0.1 0 0 2-5957 17.5 7 0 0 19.5 0 0.1 0 0 2-60 57 17.5 7 0 0 18.5 0 0.1 0 3 2-61 5717.5 7 0 0 18.5 0 0.1 0 6 2-62 53 14.5 17 1 0 14.5 0 0.1 0 0 2-63 5114.75 18 1.5 0 14.75 0 0.1 0 0 2-64 57 18.8 5 0 0 18.7 0.5 0.1 0.02 02-65 57 18 7 10 0 18 0 0.1 0 0 2-66 57 17 9 10 0 17 0 0.1 0 0 2-67 5717.5 7 4 0 18.5 0 0.1 0 0 2-68 60 15.38 0 0 0 16.49 0 0.1 0 5.15

TABLE 4 Properties of Exemplary Clad Glass Compositions CTE LiquidusDegrad'n (×10⁻⁷/ Temp Liquidus Strain Pt Anneal Soft Pt Density SampleRate (%) ° C. (° C.) Visc (kP) (° C.) Pt (° C.) (° C.) (g/cm³) 2-1 22.85 92.7 1085 573 612 668 925 2.428 2-2  16.89 92.6 1035 584 581 633881 2.410 2-3  12.55 92.6 985 824 557 608 847 2.420 2-4  23.73 92.4 950898 539 588 813 2.401 2-5  28.92 92.8 900 >2000 522 570 789 2.388 2-6 1.96 92.5 1030 776 580 634 883 2.428 2-7  0.94 89.8 970 1326 557 607 8492.427 2-8  13.67 84.7 1000 233 541 590 814 2.410 2-9  9.28 85.0910 >2000 569 624 864 2.407 2-10 6.76 88.0 790 >2000 594 648 899 2.3852-11 6.29 79.1 775 >2000 524 576 821 2.369 2-12 3.33 82.3 770 >2000 544596 842 2.350 2-13 2.13 73.0 742 >2000 493 541 779 2.330 2-14 2.53 74.9760 >2000 508 557 790 2.310 2-15 1.55 76.4 950 1106 543 591 819 2.3942-16 1.94 82.1 770 >2000 535 583 814 2.394 2-17 2.99 85.1 750 >2000 526577 819 2.392 2-18 5.25 87.0 940 >2000 528 578 836 2.388 2-19 10.31 87.71155 68 536 589 849 2.384 2-20 5.09 87.5 770 >2000 516 565 809 2.3702-21 7.15 85.8 795 >2000 513 561 789 2.377 2-22 4.59 84.6 760 >2000 514559 772 2.382 2-23 5.31 79.5 750 >2000 526 571 776 2.385 2-24 9.19 87.1750 >2000 503 552 777 2.357 2-25 5.73 86.3 775 >2000 498 544 760 2.3662-26 3.97 84.1 770 >2000 502 547 749 2.374 2-27 6.09 79.2 795 >2000 511554 744 2.377 2-28 9.89 85.4 715 >2000 491 538 760 2.348 2-29 10.74 86.5735 >2000 487 533 735 2.355 2-30 14.37 84.9 750 >2000 491 534 731 2.3642-31 9.73 79.4 790 >2000 501 544 726 2.368 2-32 5.28 81.3 765 >2000 521566 769 2.405 2-33 6.34 80.9 910 294 524 566 753 2.435 2-34 12.74 88.41000 524 555 604 837 2.425 2-35 15.12 87.8 1000 281 545 591 813 2.4392-36 14 87.4 1030 59 544 589 797 2.465 2-37 15.76 87.1 760 >2000 523 570800 2.385 2-38 17.13 88.2 750 >2000 521 571 800 2.388 2-39 17.13 90.2840 >2000 521 570 794 2.394 2-40 7.86 83.6 800 >2000 503 551 785 2.3652-41 7.84 83.1 770 >2000 495 544 770 2.361 2-42 12.58 82.8 800 >2000 492540 762 2.356 2-43 12.28 90.8 1000 773 553 601 841 2.428 2-44 12.89 91.4990 366 545 592 821 2.432 2-45 22.9 92.7 970 292 534 577 771 2.442 2-4622.1 92.1 970 149 528 572 766 2.450 2-47 24.44 94.5 960 90 524 564 7432.459 2-48 28.93 94.5 950 89 519 559 735 2.461 2-49 22.85 80.0 765 >2000493 533 712 2.367 2-50 16.21 79.3 750 >2000 484 525 702 2.355 2-51 16.8980.0 775 1171 476 517 688 2.346 2-52 8.56 82.7 935 66 534 574 736 2.4952-53 2.44 79.3 735 >2000 508 556 798 2.343 2-54 2.68 78.5 795 >2000 519561 764 2.391 2-55 2.9 77.1 840 >2000 515 557 744 2.382 2-56 2.14 75.9765 >2000 510 553 741 2.375 2-57 15.1 90.3 1010 150 534 579 798 2.4422-58 9.66 89.6 1020 85 530 573 784 2.452 2-59 16.69 93.1 1020 150 532576 791 2.439 2-60 3.02 89 800 >2000 530 581 823 2.404 2-61 0.51 87.8810 >2000 514 564 800 2.395 2-62 2.84 76.7 740 >2000 502 546 763 2.3482-63 4.19 78 775 >2000 500 542 737 2.355 2-64 15.63 94.5 970 414 609 664928 2.427 2-65 14.96 87.5 1070 10 544 584 762 2.513 2-66 13.29 83.6 99028 534 573 739 2.508 2-67 13.1 88.9 1020 42 531 574 764 2.473 2-68 0.0584.4 990 >2000 630 704 957 2.422

As shown in Tables 2 and 4, the exemplary clad glass compositions areless durable (i.e., have higher degradation rates) than the exemplarycore glass compositions in the selected reagent (i.e., 50% HCl).

A glass article is formed as described herein and comprises a coreformed from an exemplary core glass composition (e.g., Sample 1-1 to1-4) and a clad formed from an exemplary clad glass composition (e.g.,Sample 2-1 to 2-68).

Example 1

A glass article comprising a core formed from the core glass compositionof Sample 1-2 and a clad formed from the clad glass composition ofSample 2-13 is formed. The ratio of the degradation rate of the cladglass composition in the selected reagent to the degradation rate of thecore glass composition in the selected reagent is about 213. The CTE ofthe clad glass composition is about 10.6×10⁻⁷/° C. less than the CTE ofthe core glass composition.

FIG. 9 is a graphical representation of predicted clad thicknesssufficient to avoid a visible defect in the core of the glass article asa function of the amplitude and the width of a protrusion on a formingsurface. For the purposes of FIG. 9, a visible defect is a defect havinga slope of greater than 1/5000. The core to clad viscosity ratio isassumed to be 7.5.

Example 2

A glass article comprising a core formed from the core glass compositionof Sample 1-2 and a clad formed from the clad glass composition ofSample 2-49 is formed. The ratio of the degradation rate of the cladglass composition in the selected reagent to the degradation rate of thecore glass composition in the selected reagent is about 2285. The CTE ofthe clad glass composition is about 3.6×10⁻⁷/° C. less than the CTE ofthe core glass composition.

Example 3

A glass sheet having the general structure shown in FIG. 1 was formed.The core was formed from the core glass composition of Sample 1-2, andthe clad was formed from the clad glass composition of Sample 2-13. Theglass sheet had a thickness of 1 mm. The ratio of the core layerthickness to the clad layer thickness was about 7.

FIG. 10 is a graphical representation of the degradation rates of eachof the core glass composition and the clad glass composition, expressedas etch thickness as a function of time. For the purposes of FIG. 10,etch thickness is the reduction in thickness of the glass sheet inresponse to exposure of the glass sheet to a static 50 vol % aqueous HClsolution at room temperature. The degradation rate of the core glasscomposition is represented by diamond-shaped data points 330. Thedegradation rate of the clad glass composition is represented bycircular data points 332. Thus, as shown in FIG. 10, the ratio of thedegradation rate of the clad glass composition to the degradation rateof the core glass composition was greater than about 2000.

The glass sheet was formed into a molded glass article using a vacuummold. FIG. 11 is a photograph of the molded glass article. As shown inFIG. 11, the molded glass article had a dished shape comprising asubstantially planar central region encompassed by a curved lip. Themolded glass article had a hazy or cloudy appearance. Without wishing tobe bound by any theory, it is believed that the haziness is a result ofthe contact between the clad and the mold.

The clad was removed from the molded glass article by exposing themolded glass article to a reagent. FIG. 12 is a photograph of the moldedglass article following removal of the clad. The molded glass articlehad a clear appearance following removal of the clad. In other words,the haziness evident in FIG. 11 does not appear in FIG. 12.

This example demonstrates that it is possible to mold a glass articleand then etch the molded glass article to reveal a pristine core surfacewith little or no polishing following the etching process. Becausevisible surface damage is removed from the molded glass article duringremoval of the clad, such a molding and etching process can enableextended mold lifetimes, as more damage can be tolerated from the mold.

Because the core glass composition in this example is ion exchangeable,the molded glass article can be subjected to an ion exchange processfollowing removal of the clad. This can aid in strengthening the moldedglass article.

Example 4

A glass sheet having the general structure shown in FIG. 1 was formed asdescribed in Example 3. The glass sheet had a thickness of 2 mm.

The glass sheet was formed into a molded glass article by pressing theglass sheet into a graphite mold with a plunger. The molded glassarticle had a deep dished shape comprising a substantially planarcentral region encompassed by a curved lip. The bend between the centralregion and the lip was near 90°. The clad was removed from about half ofthe molded glass article by exposing the molded glass article to areagent. FIG. 13 is a photograph of the molded glass article followingremoval of the clad from half of the molded glass article. As shown inFIG. 13, the right half of the molded glass article with the clad had ahazy or cloudy appearance, and the left half of the molded glass articlewithout the clad had a clear appearance.

This example further demonstrates that it is possible to mold a glassarticle and then etch the molded glass article to reveal a pristine coresurface with little or no polishing following the etching process, evenwhen the glass article sustains substantial damage during the moldingprocess. Thus, a pristine molded glass article can be formed using arelatively low quality mold.

Example 5

A glass sheet having the general structure shown in FIG. 1 was formed asdescribed in Example 3. The glass sheet had a thickness of 1 mm. Thecore layer had a thickness of about 0.8 mm. Each of the first and secondcladding layers had a thickness of about 0.1 mm.

The glass sheet was formed into molded glass article by sagging theglass sheet onto an outer surface of a cylindrical fused silicasubstrate. FIG. 14 is a photograph of the molded glass article. As shownin FIG. 14, the molded glass article had a continuous curved shape. Themolded glass article had a hazy or cloudy appearance.

The clad was removed from the molded glass article by exposing themolded glass article to a reagent. FIG. 15 is a photograph of the moldedglass article following removal of the clad. The molded glass articlehad a clear appearance following removal of the clad.

This example further demonstrates that it is possible to mold a glassarticle and then etch the molded glass article to reveal a pristine coresurface with little or no polishing following the etching process.

It will be recognized that each exemplary clad glass composition may notbe suitable for use with each exemplary core glass composition to form aglass article within the scope of some of the embodiments describedherein. For example, the exemplary clad glass composition of Sample 2-68has a relatively low degradation rate (e.g., less than 0.9%), andtherefore, may not be suitable for use with the each exemplary coreglass composition (e.g., Samples 1-1 or 1-2) to form a glass article inwhich the ratio of the degradation rate of the second glass compositionto the degradation rate of the first glass composition is at least 10 asdescribed herein with respect to some embodiments. Also for example, theexemplary clad glass compositions of Samples 2-65 to 2-67 haverelatively low liquidus viscosities (e.g., less than 50 kP), andtherefore, may not be suitable for forming a glass article using afusion draw process as described herein with respect to someembodiments.

It will be apparent to those skilled in the art that variousmodifications and variations can be made without departing from thespirit or scope of the invention. Accordingly, the invention is not tobe restricted except in light of the attached claims and theirequivalents.

What is claimed is:
 1. A method comprising: forming a glass articlecomprising a core and a clad adjacent to the core, the core comprising acore glass composition, the clad comprising a clad glass compositiondifferent than the core glass composition; wherein the clad glasscomposition comprises from about 45 mol % to about 60 mol % SiO₂, fromabout 8 mol % to about 19 mol % Al₂O₃ and at least one alkali metaloxide selected from the group consisting of Li₂O, Na₂O, K₂O, Rb₂O, Cs₂O,and combinations thereof; wherein a degradation rate of the clad glasscomposition in a reagent is greater than a degradation rate of the coreglass composition in the reagent; wherein the clad glass compositioncomprises a coefficient of thermal expansion (CTE) of from about50×10⁻⁷/° C. to about 95×10⁻⁷/° C. and a liquidus viscosity of at leastabout 50 kP.
 2. The method of claim 1, wherein the clad glasscomposition is substantially free of As and Cd; and the degradation rateof the clad glass composition in the reagent is at least 10 timesgreater than the degradation rate of the core glass composition in thereagent.
 3. The method of claim 1, further comprising removing at leasta portion of the clad by contacting the glass article with the reagent.4. The method of claim 1, wherein the glass article comprises alaminated glass sheet, the clad comprises a first cladding layer and asecond cladding layer, and the core comprises a core layer disposedbetween the first cladding layer and the second cladding layer.
 5. Themethod of claim 4, wherein the core layer comprises an inner core layer,a first outer core layer disposed between the first cladding layer andthe inner core layer, and a second outer core layer disposed between thesecond cladding layer and the inner core layer, and wherein each of thefirst outer core layer and the second outer core layer comprises thecore glass composition.
 6. The method of claim 5, wherein each of thefirst cladding layer and the second cladding layer comprises a higherdegradation rate in the reagent than each of the first outer core layerand the second outer core layer.
 7. The method of claim 4, wherein thecore layer comprises an inner core layer, a first outer core layerdisposed between the first cladding layer and the inner core layer, anda second outer core layer disposed between the second cladding layer andthe inner core layer, each of the first cladding layer, the first outercore layer, the second cladding layer, and the second outer core layercomprises a lower CTE than the inner core layer.
 8. The method of claim1, further comprising contacting the clad of the glass article with aforming surface and subsequently removing at least a portion of the cladby contacting the glass article with the reagent.
 9. The method of claim8, further comprising determining at least one of a clad thickness or acore to clad viscosity ratio based on a surface condition of the formingsurface.
 10. The method of claim 8, further comprising subjecting theglass article to an ion exchange process subsequent to the removing atleast a portion of the clad.
 11. The method of claim 1, furthercomprising causing ion exchange between the core and the clad.
 12. Amethod comprising: contacting an outer surface of a laminated glasssheet with a glass processing unit, the laminated glass sheet comprisinga core layer disposed between a first cladding layer and a secondcladding layer, each of the first cladding layer and the second claddinglayer independently comprising from about 45 mol % to about 60 mol %SiO₂ and from about 8 mol % to about 19 mol % Al₂O₃, and at least onealkali metal oxide selected from the group consisting of Li₂O, Na₂O,K₂O, Rb₂O, Cs₂O, and combinations thereof, each of the first claddinglayer and the second cladding layer substantially free of As and Cd; andcontacting the first cladding layer and the second cladding layer with areagent to at least partially remove the first cladding layer and thesecond cladding layer, a ratio of a degradation rate of each of thefirst cladding layer and the second cladding layer in the reagent to adegradation rate of the core layer in the reagent being at least
 10. 13.The method of claim 12, wherein the glass processing unit comprises aforming unit, and the contacting the laminated glass sheet with theglass processing unit comprises engaging the laminated glass sheet witha forming surface of the forming unit to form a molded glass articlecomprising a shape that is complementary to the forming surface.
 14. Themethod of claim 13, wherein the contacting the first cladding layer andthe second cladding layer with the reagent comprises removing the firstcladding layer and the second cladding layer from the molded glassarticle.
 15. The method of claim 12, wherein the reagent issubstantially free of HF.